Compositions and aqueous dispersions

ABSTRACT

An aqueous dispersion including (A) at least one base polymer selected from the group consisting of an ethylene-based co-polymer and a propylene-based co-polymer; (B) at least one polymeric stabilizing agent; and at least one filler; wherein the polymeric stabilizing agent is different from the at least one base polymer and is compatible with the at least one base polymer and the at least one filler, and wherein the dispersion has filler in the range of greater than 0 to about 600 parts per hundred parts of a combined amount of the at least one base polymer and the polymeric stabilizing agent is disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 12/097,389, filed on Jun. 13, 2008, entitled“COMPOSITIONS AND AQUEOUS DISPERSIONS,” which is a 371 National Stage ofInternational Application No. PCT/US2006/046517, filed on Dec. 4, 2006,entitled “COMPOSITIONS AND AQUEOUS DISPERSIONS,” the teachings of whichare incorporated by reference herein as if reproduced hereinbelow, and aContinuation-in-Part application of U.S. patent application Ser. No.11/300,807, filed on Dec. 15, 2005, entitled, “COMPOSITIONS AND AQUEOUSDISPERSIONS,” the teachings of which are incorporated by referenceherein, as if reproduced in full hereinbelow.

BACKGROUND OF INVENTION

1. Field of the Invention

The present invention relates generally to aqueous dispersions thatinclude a filler. More specifically, the present invention relates todispersions that are useful in the carpet industry.

2. Background Art

Methods and techniques for carpet construction are known in the art. Avariety of types of carpets exist, including tufted and non-tuftedcarpets. Tufted carpets are composite structures that include yarn(known as a fiber bundle), a primary backing material having a facesurface and a back surface, an adhesive backing material and,optionally, a secondary backing material.

Typically, in order to form the face surface of a tufted carpet, yarn istufted through the primary backing material such that the longer lengthof each stitch extends through the face surface of the primary backingmaterial. Typically, the primary backing material is made of a woven ornon-woven material such as a thermoplastic polymer, most commonlypolypropylene.

The face of a tufted carpet is generally manufactured using one of threemethods. First, for a loop pile carpet, the yarn loops formed in thetufting process are left intact. Second, for a cut pile carpet, the yarnloops are cut, either during tufting or after, to produce a pile of yarnends instead of loops. Third, some carpet styles include both loop andcut pile. One variety of this hybrid is referred to as tip-shearedcarpet where loops of differing lengths are tufted followed by shearingthe carpet at a height so as to produce a mix of uncut, partially cut,and completely cut loops. Alternatively, the tufting machine can beconfigured so as to cut only some of the loops, thereby leaving apattern of cut and uncut loops. Whether loop, cut, or a hybrid, the yarnon the backside of the primary backing material typically comprisestight, unextended loops.

The combination of tufted yarn and a primary backing material withoutthe application of an adhesive backing material or a secondary backingmaterial is referred to in the carpet industry as raw tufted carpet orgreige goods. Greige goods become finished tufted carpet with theapplication of an adhesive backing material and an optional secondarybacking material to the backside of the primary backing material.Finished tufted carpet can be prepared as broad-loomed carpet in rollstypically 6 or 12 feet (˜2 or ˜4 meters) wide. Alternatively, carpet canbe prepared as carpet tiles, typically 18 inches (50 cm) square to 4 ft(1.3 m) square.

The adhesive backing material is typically applied to the backface ofthe primary backing material to affix the yarn to the primary backingmaterial. In one method, the adhesive backing material is applied by apan applicator using a roller, a roll over a roller or a bed, or a knife(also known as a doctor blade) over a roller or a bed. When appliedproperly, the adhesive backing material does not pass through theprimary backing material.

The adhesive backing material may be applied as a single coating orlayer or as a multiple layer. The extent or tenacity to which the yarnis affixed is referred to as “tuft lock” or tuft bind strength. Carpetswith sufficient tuft lock exhibit good wear resistance and, as such,have longer service lives. In order to have good performancecharacteristics, the adhesive backing material should substantiallypenetrate the yarn (fiber bundle) exposed on the backside of the primarybacking material and should substantially consolidate individual fiberswithin the yarn. Good penetration of the yarn and consolidation of thefibers leads to good abrasion resistance. Moreover, in addition to goodtuft bind strength and abrasion resistance, the adhesive materialpreferably imparts or allows good flexibility to the carpet in order tofacilitate installation of the carpet.

The secondary backing material is typically a lightweight scrim made ofwoven or non-woven material such as a thermoplastic polymer, mostcommonly polypropylene. The secondary backing material is optionallyapplied to the backside of the carpet onto the adhesive backingmaterial, primarily to provide enhanced dimensional stability to thecarpet structure as well as to provide more surface area for theapplication of direct glue-down adhesives.

Alternative backing materials may include foam cushioning (e.g. foamedpolyurethane) and pressure sensitive floor adhesives. Alternativebacking materials may also be applied, for example, as webbing withenhanced surface area, to facilitate direct glue-down adhesiveinstallations (e.g., in contract commercial carpeting, automobile carpetand airplane carpet where the need for cushioning is ofttimes minimal).Alternative backing materials can also be optionally applied to enhancebarrier protection with respect to moisture, insects, and foodstuffs, aswell as to provide or enhance fire suppression, thermal insulation, andsound dampening properties of the carpet.

Known adhesive backing materials include curable latex, urethane orvinyl systems, with latex systems being most common. Conventional latexsystems are low viscosity, aqueous compositions that can be applied athigh carpet production rates and offer good fiber-to-backing adhesion,tuft bind strength and adequate flexibility. Generally, excess water isdriven off and the latex is cured by passing through a drying oven.Styrene butadiene rubbers (SBR) are the most common polymers used forlatex adhesive backing materials. Typically, the latex backing system isheavily filled with an inorganic filler such as calcium carbonate oraluminum trihydrate and includes other ingredients such as antioxidants,antimicrobials, flame retardants, smoke suppressants, wetting agents,and froth aids.

Conventional latex adhesive backing systems can have certain drawbacks.As one important drawback, typical latex adhesive backing systems do notprovide a moisture barrier. Another possible drawback, particularly witha carpet having polypropylene yarn and polypropylene primary andsecondary backing materials, is the dissimilar polymer of latex systemsalong with the inorganic filler can reduce the recyclability of thecarpet. Additionally, the high molecular weights of latex systems cansignificantly reduce the recyclability.

In view of these drawbacks, some in the carpet industry have begunseeking suitable replacements for conventional latex adhesive backingsystems. One alternative is the use of urethane adhesive backingsystems. In addition to providing adequate adhesion to consolidate thecarpet, urethane backings generally exhibit good flexibility and barrierproperties and, when foamed, can eliminate the need for separateunderlayment padding (i.e., can constitute a direct glue-down unitarybacking system). However, urethane backing systems also have importantdrawbacks, including their relatively high cost and demanding curingrequirements which necessitate application at slow carpet productionrates relative to latex systems.

Thermoplastic polyolefins such as ethylene vinyl acetate (EVA)copolymers and low density polyethylene (LDPE) have also been suggestedas adhesive backing materials due in part to their low costs, goodmoisture stability and no-cure requirements. Various methods areavailable for applying polyolefin backing materials, including powdercoating, hot melt application, and extruded film or sheet lamination.However, using polyolefins to replace latex adhesive backings can alsopresent difficulties. For example, U.S. Pat. No. 5,240,530, Table A atCol. 10, indicates that ordinary polyolefin resins possess inadequateadhesion for use in carpet construction. Additionally, relative to latexand other cured systems, ordinary polyolefins have relatively highapplication viscosities and relatively high thermal requirements. Thatis, ordinary thermoplastic polyolefins are characterized by relativelyhigh melt viscosities and high recrystallization or solidificationtemperatures relative to the typical aqueous viscosities and curetemperature requirements characteristic of latex and other cured(thermosetting) sytems.

Even ordinary elastomeric polyolefins, i.e. polyolefins having lowcrystallinities, generally have relatively high viscosities andrelatively high recrystallization temperatures. High recrystallizationtemperatures result in relatively short molten times during processingand, when combined with high melt viscosities, can make it difficult toachieve adequate penetration of the yarn, especially at conventionaladhesive backing application rates.

One method for overcoming the viscosity and recrystallizationdeficiencies of ordinary polyolefins is to formulate the polyolefinresin as a hot melt adhesive. Such a method usually involves formulatinglow molecular weight polyolefins with waxes, tackifiers, various flowmodifiers and/or other elastomeric materials. Ethylene/vinyl acetate(EVA) copolymers, for example, having been used in formulated hot meltadhesive backing compositions and other polyolefins compositions havealso been proposed for use in hot melt backing compositions. Forexample, in U.S. Pat. No. 3,982,051, Taft et al. disclose that acomposition comprising an ethylene/vinyl acetate copolymer, atacticpolypropylene, and vulcanized rubber is useful as a hot melt carpetbacking adhesive.

Unfortunately, hot melt adhesive systems are not generally considered tobe complete replacements for conventional latex adhesive backings.Typical hot melt systems of EVA and other copolymers of ethylene andunsaturated comonomers can require considerable effort in formulationand often yield inadequate tuft bind strengths. Furthermore, theyrequire the purchase of new capital as they cannot be run onlatex-enabled systems. However, the most significant deficiency oftypical hot melt systems is their melt strengths, which are generallytoo low to permit application by a direct extrusion coating technique.As such, polyolefin hot melt systems are typically applied to primarybackings by relatively slow, less efficient techniques, such as by theuse of heated doctor blades or rotating melt transfer rollers.

While unformulated high pressure low density polyethylene (LDPE) can beapplied by a conventional extrusion coating technique, LDPE resinstypically have poor flexibility, which can result in excessive carpetstiffness. On the other hand, those polyolefins that have improvedflexibility, such as ultra low density polyethylene (ULDPE) andethylene/propylene interpolymers, still do not possess sufficientflexibility, have excessively low melt strengths, and/or tend to drawresonate during extrusion coating. To overcome extrusion coatingdifficulties, ordinary polyolefins with sufficient flexibility can beapplied by lamination techniques to insure adequate yarn-to-backingadhesion; however, lamination techniques are typically expensive and canresult in reduced production rates relative to direct extrusion coatingtechniques.

Known examples of flexible polyolefin backing materials are disclosed inU.S. Pat. Nos. 3,390,035; 3,583,936; 3,745,054; and 3,914,489. Ingeneral, these disclosures describe hot melt adhesive backingcompositions based on an ethylene copolymer, such as ethylene/vinylacetate (EVA), and waxes. Known techniques for enhancing the penetrationof hot melt adhesive backing compositions in the yarn include applyingpressure while the greige good is in contact with rotating melt transferrollers as described, for example, in U.S. Pat. No. 3,551,231.

Another known technique for enhancing the effectiveness of hot meltsystems involve using pre-coat systems. For example, U.S. Pat. Nos.3,684,600; 3,583,936; and 3,745,054, describe the application of lowviscosity aqueous pre-coats to the back surface of a primary backingmaterial prior to the application of a hot melt adhesive composition.The hot melt adhesive backing systems disclosed in these patents arederived from multi-component formulations based on functional ethylenepolymers such as, ethylene/ethyl acrylate (EEA) and ethylene/vinylacetate (EVA) copolymers.

Another prior art method for manufacturing carpet is disclosed in PCTPublication No. 98/38376, which discloses an extrusion coating techniquethat uses a homogeneously branched linear ethylene polymer as a backingmaterial. That application discloses using particle sizes in the 18 to22 micron range and formulating a particle in water slurry.

Although there are various systems known in the art of carpet backings,there remains a need for a thermoplastic polyolefin carpet backingsystem, which provides adequate tuft bind strength, good abrasionresistance and good flexibility, to replace cured latex backing systems.A need also remains for an application method that permits high carpetproduction rates while achieving the desired characteristics of goodtuft bind strength, abrasion resistance, barrier properties andflexibility. Finally, there is also a need for a carpet structure havingfibers and backing materials that are easily recyclable without thenecessity of extensive handing and segregation of carpet componentmaterials.

SUMMARY OF INVENTION

In one aspect, the present invention relates to a compound including (A)at least one base polymer selected from the group consisting of anethylene-based co-polymer and a propylene-based co-polymer; (B) at leastone polymeric stabilizing agent; and at least one filler; wherein thepolymeric stabilizing agent is different from the at least one basepolymer and is compatible with the at least one base polymer and the atleast one filler, and wherein the dispersion has filler in the range ofgreater than 0 to about 600 parts per hundred parts of a combined amountof the at least one base polymer and the polymeric stabilizing agent.

In one aspect, the present invention relates to a method of applying acompound to a substrate that includes forming an aqueous dispersion, theaqueous dispersion including (A) at least one base polymer selected fromthe group consisting of an ethylene-based co-polymer and apropylene-based co-polymer; (B) at least one polymeric stabilizingagent; and at least one filler; wherein the polymeric stabilizing agentis different from the at least one base polymer and is compatible withthe at least one base polymer and the at least one filler, and whereinthe dispersion has filler in the range of greater than 0 to about 600parts per hundred parts of a combined amount of the at least one basepolymer and the polymeric stabilizing agent; frothing the mixture with agas; and applying the frothed mixture to a substrate.

Other aspects and advantages of the invention will be apparent from thefollowing description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows an extruder that may be used in formulating dispersions inaccordance with embodiments of the present invention.

FIG. 2 shows a flowchart illustrating a method in accordance with anembodiment of the present invention.

FIG. 3 shows a comparison of embodiments of the present invention withprior art compositions.

DETAILED DESCRIPTION

Embodiments of the present invention relate to compositions that includea base polymer, a stabilizing agent, and a filler. The compositions thusformed are particularly useful in the carpet industry. With respect tothe carpet industry, embodiments of the present invention are useful forneedlepunch, weaved, and/or tufted carpets, including artificial turf.Further, specific terminology used in relation to the carpet industry ismeant to be construed in accordance with the Dictionary of Fibers andTextile Technology, Product/Technical Communications Services IZ 503,Hoescht Celanese Corporation, Charlotte, N.C. 1990.

Briefly, as used herein, the term needlepunching refers to the processof converting batts or webs of loose fibers into a coherent non wovenfabric on a needle loom. Weaving refers to the method or process ofinterlacing two yarns so that they cross each other to produce wovenfabric. The warp yarns, or ends, run lengthwise in the fabric and thefilling threads (weft) or picks, run from side to side. Finally, as usedherein, tufting refers to the process of making carpet fabric bystitching a pile yarn through a primary backing cloth using needles toform rows of tufts.

Base Polymers

Embodiments of the present invention employ polyethylene-based polymers,polypropylene-based polymers, and propylene-ethylene copolymers as onecomponent of a composition.

In selected embodiments, one component is formed from ethylene-alphaolefin copolymers or propylene-alpha olefin copolymers. In particular,in preferred embodiments, the base polymer comprises one or morenon-polar polyolefins.

In specific embodiments, polyolefins such as polypropylene,polyethylene, and copolymers thereof, and blends thereof, as well asethylene-propylene-diene terpolymers, may be used. In some embodiments,preferred olefinic polymers include homogeneous polymers described inU.S. Pat. No. 3,645,992 issued to Elston; high density polyethylene(HDPE) as described in U.S. Pat. No. 4,076,698 issued to Anderson;heterogeneously branched linear low density polyethylene (LLDPE);heterogeneously branched ultra low linear density polyethylene (ULDPE);homogeneously branched, linear ethylene/alpha-olefin copolymers;homogeneously branched, substantially linear ethylene/alpha-olefinpolymers, which can be prepared, for example, by a process disclosed inU.S. Pat. Nos. 5,272,236 and 5,278,272, the disclosures of which areincorporated herein by reference; and high pressure, free radicalpolymerized ethylene polymers and copolymers such as low densitypolyethylene (LDPE).

Polymer compositions described in U.S. Pat. Nos. 6,538,070, 6,566,446,5,869,575, 6,448,341, 5,677,383, 6,316,549, 6,111,023, or 5,844,045,each of which is incorporated herein by reference in its entirety, arealso suitable in some embodiments. Of course, blends of polymers can beused as well. In some embodiments, the blends include two differentZiegler-Natta polymers. In other embodiments, the blends can includeblends of a Ziegler-Natta and a metallocene polymer. In still otherembodiments, the polymer used herein is a blend of two differentmetallocene polymers. In other embodiments single site catalysts may beused.

In some particular embodiments, the polymer is a propylene-basedcopolymer or interpolymer. In some embodiments, the propylene/ethylenecopolymer or interpolymer is characterized as having substantiallyisotactic propylene sequences. The term “substantially isotacticpropylene sequences” and similar terms mean that the sequences have anisotactic triad (mm) measured by ¹³C NMR of greater than about 0.85,preferably greater than about 0.90, more preferably greater than about0.92 and most preferably greater than about 0.93. Isotactic triads arewell-known in the art and are described in, for example, U.S. Pat. No.5,504,172 and WO 00/01745, which refer to the isotactic sequence interms of a triad unit in the copolymer molecular chain determined by ¹³CNMR spectra.

In other particular embodiments, the base polymer may be ethylene vinylacetate (EVA) based polymers.

In other selected embodiments, olefin block copolymers, e.g. ethylenemulti-block copolymer, such as those described in the InternationalPublication No. WO2005/090427 and U.S. patent application Ser. No.11/376,835 may be used as the base polymer. Such olefin block copolymermay be an ethylene/α-olefin interpolymer:

(a) having a Mw/Mn from about 1.7 to about 3.5, at least one meltingpoint, Tm, in degrees Celsius, and a density, d, in grams/cubiccentimeter, wherein the numerical values of Tm and d corresponding tothe relationship:

Tm>−2002.9+4538.5(d)−2422.2(d)²; or

(b) having a Mw/Mn from about 1.7 to about 3.5, and being characterizedby a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degreesCelsius defined as the temperature difference between the tallest DSCpeak and the tallest CRYSTAF peak, wherein the numerical values of ΔTand ΔH having the following relationships:

ΔT>−0.1299(ΔH)+62.81 for ΔH greater than zero and up to 130 J/g,

ΔT≧48° C. for ΔH greater than 130 J/g,

wherein the CRYSTAF peak being determined using at least 5 percent ofthe cumulative polymer, and if less than 5 percent of the polymer havingan identifiable CRYSTAF peak, then the CRYSTAF temperature being 30° C.;or

(c) being characterized by an elastic recovery, Re, in percent at 300percent strain and 1 cycle measured with a compression-molded film ofthe ethylene/α-olefin interpolymer, and having a density, d, ingrams/cubic centimeter, wherein the numerical values of Re and dsatisfying the following relationship when ethylene/α-olefininterpolymer being substantially free of a cross-linked phase:

Re>1481-1629(d); or

(d) having a molecular fraction which elutes between 40° C. and 130° C.when fractionated using TREF, characterized in that the fraction havinga molar comonomer content of at least 5 percent higher than that of acomparable random ethylene interpolymer fraction eluting between thesame temperatures, wherein said comparable random ethylene interpolymerhaving the same comonomer(s) and having a melt index, density, and molarcomonomer content (based on the whole polymer) within 10 percent of thatof the ethylene/α-olefin interpolymer; or

(e) having a storage modulus at 25° C., G′(25° C.), and a storagemodulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) toG′(100° C.) being in the range of about 1:1 to about 9:1.

The ethylene/α-olefin interpolymer may also:

(a) having a molecular fraction which elutes between 40° C. and 130° C.when fractionated using TREF, characterized in that the fraction havinga block index of at least 0.5 and up to about 1 and a molecular weightdistribution, Mw/Mn, greater than about 1.3; or

(b) having an average block index greater than zero and up to about 1.0and a molecular weight distribution, Mw/Mn, greater than about 1.3.

Those having ordinary skill in the art will recognize that the abovelist is a non-comprehensive listing of suitable polymers. It will beappreciated that the scope of the present invention is restricted by theclaims only.

Stabilizing Agent

Embodiments of the present invention use a stabilizing agent. Inselected embodiments, the stabilizing agent may be a surfactant, apolymer (different from the base polymer detailed above) having a polargroup as either a comonomer or grafted monomer, or mixtures thereof. Inpreferred embodiments, the stabilizing agent comprises one or more polarpolyolefins. Typical polymers include ethylene-acrylic acid (EAA) andethylene-methacrylic acid copolymers, such as those available under thetradenames PRIMACOR™, Nucrel™, and Escor™ and described in U.S. Pat.Nos. 4,599,392, 4,988,781, and 5,938,437, each of which is incorporatedherein by reference in its entirety. Other polymers include ethyleneethyl acrylate (EEA) copolymer, ethylene methyl methacrylate (EMMA), andethylene butyl acrylate (EBA). Those having ordinary skill in the artwill recognize that a number of other useful polymers may also be used.

If the polar group of the polymer is acidic or basic in nature, thestabilizing polymer may be partially or fully neutralized with aneutralizing agent to form the corresponding salt. For example, for EAA,the neutralizing agent is a base, such as ammonium hydroxide orpotassium hydroxide, for example. In another alternative, theneutralizing agent may, for example, be any amine such asmonoethanolamine, or 2-amino-2-methyl-1-propanol (AMP). Those havingordinary skill in the art will appreciate that the selection of anappropriate neutralizing agent depends on the specific compositionformulated, and that such a choice is within the knowledge of those ofordinary skill in the art.

Additional surfactants that may be useful in the practice of the presentinvention include cationic surfactants, anionic surfactants, or anon-ionic surfactants. Examples of anionic surfactants includesulfonates, carboxylates, and phosphates. Examples of cationicsurfactants include quaternary amines. Examples of non-ionic surfactantsinclude block copolymers containing ethylene oxide and siliconesurfactants. Surfactants useful in the practice of the present inventioncan be either external surfactants or internal surfactants. Externalsurfactants are surfactants that do not become chemically reacted intothe polymer during dispersion preparation. Examples of externalsurfactants useful herein include salts of dodecyl benzene sulfonic acidand lauryl sulfonic acid salt. Internal surfactants are surfactants thatdo become chemically reacted into the polymer during dispersionpreparation. An example of an internal surfactant useful herein includes2,2-dimethylol propionic acid and its salts.

Fillers

Embodiments of the present invention employ a filler as part of thecomposition. In the practice of the present invention, a suitable fillerloading in a polyolefin dispersion can be from about 0 to about 600parts of filler per hundred parts of polyolefin. The filler material caninclude conventional fillers such as milled glass, calcium carbonate,aluminum trihydrate, talc, bentonite, antimony trioxide, kaolin, flyash, or other known fillers.

Formulations

In preferred formulations, therefore, compounds in accordance with thepresent invention may include a base polymer, which comprises one ormore non-polar polyolefins, a stabilizing agent, which comprises one ormore polar polyolefins, and a filler. With respect to the base polymerand the stabilizing agent, in preferred embodiments, the one or morenon-polar polyolefin may comprise between about 30% to 99% (by weight)of the total amount of base polymer and stabilizing agent in thecomposition. More preferably, the one or more non-polar polyolefinscomprise between about 50% and about 80%. Still more preferably, the oneor more non-polar polyolefins comprise about 70%.

With respect to the filler, typically, an amount greater than about 0 toabout 1000 parts per hundred of the polymer (polymer meaning here thenon-polar polyolefin combined with the stabilizing agent) is used. Inselected embodiments, between about 50 to 250 parts per hundred areused. In selected embodiments, between about 10 to 500 parts per hundredare used. In still other embodiments, from between about 20 to 400 partsper hundred are used.

These solid materials are preferably dispersed in a liquid medium, whichin preferred embodiments is water. In preferred embodiments, sufficientbase is added to neutralize the resultant dispersion to achieve a pHrange of between about 6 to about 14. In preferred embodiments,sufficient base is added to maintain a pH of between about 9 to about12. Water content of the dispersion is preferably controlled so that thesolids content is between about 1% to about 74% (by volume). In anotherembodiment, the solid content is between about 25% to about 74% (byvolume). In particularly preferred embodiments, the solids range isbetween about 30% to about 50% (without filler, by weight).

Dispersions formed in accordance with embodiments of the presentinvention are characterized in having an average particle size ofbetween about 0.3 to about 3.0 microns. In other embodiments,dispersions have an average particle size of from about 0.8 μm to about1.2 μm. By “average particle size”, the present invention means thevolume-mean particle size. In order to measure the particle size,laser-diffraction techniques may be employed for example. A particlesize in this description refers to the diameter of the polymer in thedispersion. For polymer particles that are not spherical, the diameterof the particle is the average of the long and short axes of theparticle. Particle sizes can be measured on a Beckman-Coulter LS230laser-diffraction particle size analyzer or other suitable device.

For example, a formulation of the present invention can includesurfactants, frothing agents, dispersants, thickeners, fire retardants,pigments, antistatic agents, reinforcing fibers, antioxidants, aneutralizing agent, a rheology modifier, preservatives, biocides, acidscavengers, a wetting agent, and the like. While optional for purposesof the present invention, other components can be highly advantageousfor product stability during and after the manufacturing process.

In addition, embodiments of the present invention optionally include afiller wetting agent. A filler wetting agent generally may help make thefiller and the polyolefin dispersion more compatible. Useful wettingagents include phosphate salts, such as sodium hexametaphosphate. Afiller wetting agent can be included in a composition of the presentinvention at a concentration of at least about 0.5 part per 100 parts offiller, by weight.

Furthermore, embodiments of the present invention may optionally includea thickener. Thickeners can be useful in the present invention toincrease the viscosity of low viscosity dispersions. Thickeners suitablefor use in the practice of the present invention can be any known in theart such as for instance poly-acrylate type or associate non ionicthickeners such as modified cellulose ethers. For example, suitablethickeners include ALCOGUM™ VEP-II (trade name of Alco ChemicalCorporation), Rheovis™ and Viscalex™ (trade names of Ciba Ceigy), UCAR®Thickener 146, or Ethocell™ or Methocell™ (trade names of the DowChemical Company) and PARAGUM™ 241 (trade name of Para-Chem Southern,Inc.), or Bermacol™ (trademark of Akzo Nobel) or Aqualon™ (trademarkHercules) or ACUSOL® (trademark Rohm and Haas). Thickeners can be usedin any amount necessary to prepare a compound of desired viscosity.

The ultimate viscosity of the dispersion is, therefore, controllable.Addition of the thickener to the dispersion including the amount offiller can be done with conventional means to result in viscosities asneeded for the carpet coating. Viscosities of thus compounds can reach+3000 cP (brookfield spindle 4 with 20 rpm) with moderate thickenerdosing (up to 4% preferably, below 3% based on 100 phr of polymerdispersion). The starting polymer dispersion as described has an initialviscosity prior to formulation with fillers and additives between 20 and1000 cP (brookfield viscosity measured at room temperature with spindlerv3 at 50 rpm). Still more preferably, the starting viscosity of thedispersion may be between about 100 to about 600 cP.

Also, embodiments of the present invention are characterized by theirstability when a filler is added to the polymer/stabilizing agent. Inthis context, stability refers to the stability of viscosity of theresultant aqueous polyolefin dispersion. In order to test the stability,the viscosity is measured over a period of time. Preferably, viscositymeasured at 20° C. should remain +/−10% of the original viscosity over aperiod of 24 hours, when stored at ambient temperature.

In a specific embodiment, a base polymer, a stabilizing agent, and afiller are melt-kneaded in an extruder along with water and aneutralizing agent, such as ammonia, potassium hydroxide, or acombination of the two to form a dispersion compound. Those havingordinary skill in the art will recognize that a number of otherneutralizing agents may be used. In some embodiments, the filler may beadded after blending the base polymer and stabilizing agent.

Any melt-kneading means known in the art may be used. In someembodiments, a kneader, a Banbury mixer, single-screw extruder, or amulti-screw extruder is used. A process for producing the dispersions inaccordance with the present invention is not particularly limited. Onepreferred process, for example, is a process comprising melt-kneadingthe above-mentioned components according to U.S. Pat. No. 5,756,659 andU.S. Patent Publication No. 20010011118.

FIG. 1 schematically illustrates an extrusion apparatus that may be usedin embodiments of the invention. An extruder 20, in certain embodimentsa twin screw extruder, is coupled to a back pressure regulator, meltpump, or gear pump 30. Embodiments also provide a base reservoir 40 andan initial water reservoir 50, each of which includes a pump (notshown). Desired amounts of base and initial water are provided from thebase reservoir 40 and the initial water reservoir 50, respectively. Anysuitable pump may be used, but in some embodiments a pump that providesa flow of about 150 cc/min at a pressure of 240 bar is used to providethe base and the initial water to the extruder 20. In other embodiments,a liquid injection pump provides a flow of 300 cc/min at 200 bar or 600cc/min at 133 bar. In some embodiments, the base and initial water arepreheated in a preheater.

Advantageously, by using an extruder in certain embodiments, the basepolymer and the stabilizing agent may be blended in a single process toform a dispersion. Also, advantageously, by using one or more of thestabilizing agents listed above, the dispersion is stable with respectto the filler and other additives. Prior formulations involvingpolyolefin base polymers were unstable with respect to the filler.

Advantageously, polyolefin dispersions formed in accordance with theembodiments disclosed herein provide the ability to apply the dispersionto carpet samples and achieve good tuft lock, to adhere to primary andsecondary backing, and to maintain a flexible laminate. In specificembodiments, the inventors have also discovered that compounds disclosedherein have good adhesion to polar substrates (such as the polyamidesused for face fibers).

In a specific embodiment, a polyolefin dispersion is applied to a carpetusing any application method known to those skilled in the art. Forexample, in one embodiment, in preparing polymer backed carpetsaccording to the present invention, a polyolefin dispersion is appliedas a layer of preferably uniform thickness onto the non-pile surface ofa suitably prepared carpet substrate. Polyolefin precoats, laminatecoats, and foam coats can be prepared by methods known to those ofordinary skill in the art of preparing such backings. Precoats, laminatecoats and foam coats prepared from dispersions are described in P. L.Fitzgerald, “Integral Dispersion Foam Carpet Cushioning”, J. Coat. Fab.1977, Vol. 7 (pp. 107-120), and in R. P. Brentin, “Dispersion CoatingSystems for Carpet Backing”, J. Coat. Fab. 1982, Vol. 12 (pp. 82-91).

When preparing foams, it is often preferred to froth the dispersion.Preferred in the practice of this invention is the use of a gas as afrothing agent. Examples of suitable frothing agents include: gasesand/or mixtures of gases such as, air, carbon dioxide, nitrogen, argon,helium, and the like. Particularly preferable is the use of air as afrothing agent. Frothing agents are typically introduced by mechanicalintroduction of a gas into a liquid to form a froth. This technique isknown as mechanical frothing. In preparing a frothed polyolefin backing,it is preferred to mix all components and then blend the air or gas intothe mixture, using equipment such as an OAKES, MONDO or FIRESTONEfrother.

Surfactants useful for preparing a stable froth are referred to hereinas foam stabilizers. Foam stabilizers are useful in the practice of thepresent invention. Those having ordinary skill in this field willrecognize that a number of foam stabilizers may be used. Foamstabilizers can include, for example, sulfates, succinamates, andsulfosuccinamates.

In one embodiment of the present invention, shown in flowchart form inFIG. 2, a polyolefin dispersion is formed (ST 200). Next, the dispersionis frothed (ST 210), which may, for example, be done by mechanicallymixing with air. The frothed dispersion is then spread onto a carpet (ST220). In selected embodiments, the polyolefin dispersion is applied atabout 65° C. to about 125° C. In preferred embodiments, the polyolefindispersion is applied at about 85° C. to about 95° C.

The dispersion applied onto a substrate, e.g. a carpet, may be dried viaany conventional drying method. Such conventional drying methods includebut, are not limited to, air drying, convection oven drying, hot airdrying, microwave oven drying, and/or infrared oven drying. Thedispersion applied onto a substrate, e.g. a carpet, may be dried at anytemperature; for example, it may be dried at a temperature in the rangeof equal or greater than the melting point temperature of the basepolymer; or in the alternative, it may be dried at a temperature in therange of less than the melting point of the base polymer. The dispersionapplied onto a substrate, e.g. a carpet, may be dried at a temperaturein the range of about 60° F. (15.5° C.) to about 700° F. (371° C.). Allindividual values and subranges from about 60° F. (15.5° C.) to about700° F. (371° C.) are included herein and disclosed herein; for example,the dispersion applied onto a substrate, e.g. a carpet, may be dried ata temperature in the range of about 60° F. (15.5° C.) to about 500° F.(260° C.), or in the alternative, the dispersion applied onto asubstrate, e.g. a carpet, may be dried at a temperature in the range ofabout 60° F. (15.5° C.) to about 450° F. (232.2° C.). The temperature ofthe dispersion applied onto a substrate, e.g. a carpet, may be raised toa temperature in the range of equal or greater than the melting pointtemperature of the base polymer for a period of less than about 40minutes. All individual values and subranges from less than about 40minutes are included herein and disclosed herein; for example, thetemperature of the dispersion applied onto a substrate, e.g. a carpet,may be raised to a temperature in the range of equal or greater than themelting point temperature of the base polymer for a period of less thanabout 20 minutes, or in the alternative, the temperature of thedispersion applied onto a substrate, e.g. a carpet, may be raised to atemperature in the range of equal or greater than the melting pointtemperature of the base polymer for a period of less than about 10minutes, or in another alternative, the temperature of the dispersionapplied onto a substrate, e.g. a carpet, may be raised to a temperaturein the range of equal or greater than the melting point temperature ofthe base polymer for a period in the range of about 0.5 to 600 seconds.In another alternative, the temperature of the dispersion applied onto asubstrate, e.g. a carpet, may be raised to a temperature in the range ofless than the melting point temperature of the base polymer for a periodof less than 40 minutes. All individual values and subranges from lessthan about 40 minutes are included herein and disclosed herein; forexample, the temperature of the dispersion applied onto a substrate,e.g. a carpet, may be raised to a temperature in the range of less thanthe melting point temperature of the base polymer for a period of lessthan about 20 minutes, or in the alternative, the temperature of thedispersion applied onto a substrate, e.g. a carpet, may be raised to atemperature in the range of less than the melting point temperature ofthe base polymer for a period of less than about 10 minutes, or inanother alternative, the temperature of the dispersion applied onto asubstrate, e.g. a carpet, may be raised to a temperature in the range ofless than the melting point temperature of the base polymer for a periodin the range of about 0.5 to 600 seconds.

Drying the dispersion applied onto a substrate, e.g. a carpet, at atemperature in the range of equal or greater than the melting pointtemperature of the base polymer is important because it facilitates theformation of a film having a continuous base polymer phase with adiscrete stabilizing agent phase dispersed therein the continuous basepolymer phase thereby improving the oil and grease resistance as well asproviding a barrier for moisture and vapor transmission.

EXAMPLES

A precoat was applied to a sample of tufted carpet, using a polyolefindispersion, referred to as TCR 002. The polyolefin dispersion compriseda base polymer/stabilizing agent mix formed from AFFINITY™8200/PRIMACOR™ 5980i in a 70% to 30% blend (by weight), both of whichare available from The Dow Chemical Company (Midland, Mich.). The tuftedcarpet had polypropylene pile and polypropylene backing. Thethermoplastic polymer, AFFINITY™ 8200, as delivered consisted of soft,flexible beads. PRIMACOR™ 5980i, as delivered consisted of hard,spherical beads.

A 25 wt. % KOH stock solution was prepared to neutralize the surfactant.The final density of this solution was 1.25 g/ml at 20° C. Thispreparation is shown in Table 1 below:

TABLE 1 Preparation of a 25 wt. % KOH stock solution. Material Wt. (g)Wt. Fraction 45 wt. % KOH 555.0 0.555 Deionized water 445.0 0.445 1000.01.000

The polymer, AFFINITY™ 8200 was to be fed through a primary solidsfeeder. This feeder consisted of a Schenck loss-in-weight feeder whilethe PRIMACOR™5980i was to be fed through secondary solids feeder. Thissecondary feeder, Schenck Model 301/304, was set to deliver PRIMACOR™5980i at the desired ratio. During this setup, the AFFINITY™8200/PRIMACOR™ 5980i ratio was to be varied from 70/30 to 85/15 (byweight). Alltech 301 macro-head HPLC pumps metered all aqueous streams.The water or water/KOH mixture was pumped into the twin-screw extruderthough a tappet style injector design.

This aqueous stream was pre-heated through a 24″ core/shell heatexchanger (20′ ⅛ tubing core) tempered by a DC200 Silicone oil bath setat 190° C. Additionally, the backpressure regulator previouslyinstalled, located immediately upstream from the injector, and was setto a value of 550 psi. The dilution stream was also pre-heated with anidentical exchanger/bath setup heated to 150° C. Secondary dilution wasalso used for this experiment. A temperature/pressure probe located inZone 7 (e-zone) was used to determine the effect of pressure on finalparticle size. The melt pump controlling the extruder backpressureconsisted of a Zenith series pump with a 2.92 cc/rev capacity.

During the experiment, the IA/Feed Ratio was varied from 0.467-0.098.The PRIMACOR™ 5980i concentration was varied from 30-15 wt % of thetotal polymer. The base addition was also varied from 9.6-4.5 ml/min ofthe 25 wt. % KOH stock solution (3.000-1.406 g KOH/min). The molarneutralization varied from 198.9-90.1. Several samples were obtainedduring these water/base/PRIMACOR™ 5980i variations. These samples weremeasured on a Coulter LS230 light-scattering particle analyzer,implementing the epoxy model, after suitable dilution in a prepared0.025 wt. % KOH solution.

Particle Size

The smallest particle size achieved at 30 wt % PRIMACOR™ 5980i was 0.67μm with a polydispersity of 2.20 at an IA/Polymer ratio of 0.321 and ascrew speed of 450 rpm. At 15 wt % PRIMACOR™ 5980i, the smallestparticle size achieved was 4.18 μm with a polydispersity of 13.30 at anIA/Polymer ratio of 0.240 and a screw speed of 450 rpm.

Neutralization Level

The PRIMACOR™ 5980i at 30 wt % was partially neutralized with caustic ata level of 90.1 molar %. The calculated 100% neutralization level was tobe 3.016 g/min of KOH compared to the metered quantity of 2.719. At 15wt %, the PRIMACOR™ 5980i was partially neutralized with caustic at alevel of 93.2 molar %. The calculated 100% neutralization level was tobe 1.508 g/min of KOH compared to the metered quantity of 1.406.

Sampling

Five-gallon samples were obtained with the following specification(after post-dilution and preservative addition).

Concentration (wt %) Constituent AFFINITY ™ 8200 32.1 PRIMACOR ™ 5980i13.8 Water 54.1 DOWICIL ® 200  0.02 Sample Specifications Avg. ParticleSize (μm)  0.75 Polydispersity (Dv/Dn)  2.26 Solid Content (wt. %) 45.9pH 10.7 Viscosity (cp) 1860*   *RV3 spindle, 22.1° C., 50 rpm

Three versions of this dispersion were made: First, an unfilled (i.e.,no filler added) version was deposited onto a carpet sample. Second, asample was made using 200 parts per hundred (with respect to the basepolymer and stabilizing agent) of calcium carbonate filler, and a thirdsample was made using 200 parts per hundred (with respect to the basepolymer and stabilizing agent) aluminum trihydrate. 0.25 parts perhundred of Alcopol® O wetting agent, available from Ciba SpecialtyChemicals (Basel, Switzerland), was added to the second and thirdsamples. A number of comparison samples were also generated and testingwas performed.

DESCRIPTION OF TESTING/SPECIFICS ON EACH OF THE BELOW SAMPLES

Sample # Description of Polymer Dispersion Filler 1 ConventionalEthylene vinyl acetate None dispersion 2 PRIMACOR ™ 3460 DMD dispersionNone at +45% solids KOH neutralized 3 SBS block copolymer None 4ENGAGE ™ 8130 None 5 Techseal (which is a PRIMACOR ™ None 5980dispersion, KOH neutralized 40% solids) 6 Nitrile latex None 7PRIMACOR ™ 3460/DL 552 latex None 8 SBS/DL 552 None 9 ENGAGE ™ 8130/DL552 latex None 10 Techseal/DL 552 None 11 Nitrile latex/DL 552 None 13TCR 002 200 parts per hundred aluminum trihydrate 14 TCR 002 None 15 TCR002 200 parts per hundred calcium carbonate

Results of the test are displayed in FIG. 3. As shown in that figure,embodiments formulated in accordance with the present invention (13 and15 in the table above) showed good adhesion and tuftlock.

Advantageously, one or more embodiments of the present invention providecompositions, methods, and articles having good performance in theirintended applications. In one application, for example, one or moreembodiments of the present invention may be used on carpets in theautomotive industry.

Standard CRYSTAF Method

Branching distributions are determined by crystallization analysisfractionation (CRYSTAF) using a CRYSTAF 200 unit commercially availablefrom PolymerChar, Valencia, Spain. The samples are dissolved in 1,2,4trichlorobenzene at 160° C. (0.66 mg/mL) for 1 hr and stabilized at 95°C. for 45 minutes. The sampling temperatures range from 95 to 30° C. ata cooling rate of 0.2° C./min. An infrared detector is used to measurethe polymer solution concentrations. The cumulative solubleconcentration is measured as the polymer crystallizes while thetemperature is decreased. The analytical derivative of the cumulativeprofile reflects the short chain branching distribution of the polymer.

The CRYSTAF peak temperature and area are identified by the peakanalysis module included in the CRYSTAF Software (Version 2001.b,PolymerChar, Valencia, Spain). The CRYSTAF peak finding routineidentifies a peak temperature as a maximum in the dW/dT curve and thearea between the largest positive inflections on either side of theidentified peak in the derivative curve. To calculate the CRYSTAF curve,the preferred processing parameters are with a temperature limit of 70°C. and with smoothing parameters above the temperature limit of 0.1, andbelow the temperature limit of 0.3.

Flexural/Secant Modulus/Storage Modulus

Samples are compression molded using ASTM D 1928. Flexural and 2 percentsecant moduli are measured according to ASTM D-790. Storage modulus ismeasured according to ASTM D 5026-01 or equivalent technique.

DSC Standard Method

Differential Scanning Calorimetry results are determined using a TAImodel Q1000 DSC equipped with an RCS cooling accessory and anautosampler. A nitrogen purge gas flow of 50 ml/min is used. The sampleis pressed into a thin film and melted in the press at about 175° C. andthen air-cooled to room temperature (25° C.). 3-10 mg of material isthen cut into a 6 mm diameter disk, accurately weighed, placed in alight aluminum pan (ca 50 mg), and then crimped shut. The thermalbehavior of the sample is investigated with the following temperatureprofile. The sample is rapidly heated to 180° C. and held isothermal for3 minutes in order to remove any previous thermal history. The sample isthen cooled to −40° C. at 10° C./min cooling rate and held at −40° C.for 3 minutes. The sample is then heated to 150° C. at 10° C./min.heating rate. The cooling and second heating curves are recorded.

The DSC melting peak is measured as the maximum in heat flow rate (W/g)with respect to the linear baseline drawn between −30° C. and end ofmelting. The heat of fusion is measured as the area under the meltingcurve between −30° C. and the end of melting using a linear baseline.

Calibration of the DSC is done as follows. First, a baseline is obtainedby running a DSC from −90° C. without any sample in the aluminum DSCpan. Then 7 milligrams of a fresh indium sample is analyzed by heatingthe sample to 180° C., cooling the sample to 140° C. at a cooling rateof 10° C./min followed by keeping the sample isothermally at 140° C. for1 minute, followed by heating the sample from 140° C. to 180° C. at aheating rate of 10° C. per minute. The heat of fusion and the onset ofmelting of the indium sample are determined and checked to be within0.5° C. from 156.6° C. for the onset of melting and within 0.5 J/g from28.71 J/g for the of fusion. Then deionized water is analyzed by coolinga small drop of fresh sample in the DSC pan from 25° C. to −30° C. at acooling rate of 10° C. per minute. The sample is kept isothermally at−30° C. for 2 minutes and heat to 30° C. at a heating rate of 10° C. perminute. The onset of melting is determined and checked to be within 0.5°C. from 0° C.

GPC Method

The gel permeation chromatographic system consists of either a PolymerLaboratories Model PL-210 or a Polymer Laboratories Model PL-220instrument. The column and carousel compartments are operated at 140° C.Three Polymer Laboratories 10-micron Mixed-B columns are used. Thesolvent is 1,2,4 trichlorobenzene. The samples are prepared at aconcentration of 0.1 grams of polymer in 50 milliliters of solventcontaining 200 ppm of butylated hydroxytoluene (BHT). Samples areprepared by agitating lightly for 2 hours at 160° C. The injectionvolume used is 100 microliters and the flow rate is 1.0 ml/minute.

Calibration of the GPC column set is performed with 21 narrow molecularweight distribution polystyrene standards with molecular weights rangingfrom 580 to 8,400,000, arranged in 6 “cocktail” mixtures with at least adecade of separation between individual molecular weights. The standardsare purchased from Polymer Laboratories (Shropshire, UK). Thepolystyrene standards are prepared at 0.025 grams in 50 milliliters ofsolvent for molecular weights equal to or greater than 1,000,000, and0.05 grams in 50 milliliters of solvent for molecular weights less than1,000,000. The polystyrene standards are dissolved at 80° C. with gentleagitation for 30 minutes. The narrow standards mixtures are run firstand in order of decreasing highest molecular weight component tominimize degradation. The polystyrene standard peak molecular weightsare converted to polyethylene molecular weights using the followingequation (as described in Williams and Ward, J. Polym. Sci., Polym.Let., 6, 621 (1968)): M_(polyethylene)=0.431 (M_(polystyrene)).

Polyethylene equivalent molecular weight calculations are performedusing Viscotek TriSEC software Version 3.0.

Density

Samples for density measurement are prepared according to ASTM D 1928.Measurements are made within one hour of sample pressing using ASTMD792, Method B.

ATREF

Analytical temperature rising elution fractionation (ATREF) analysis isconducted according to the method described in U.S. Pat. No. 4,798,081and Wilde, L.; Ryle, T. R.; Knobeloch, D. C.; Peat, I. R.; Determinationof Branching Distributions in Polyethylene and Ethylene Copolymers, J.Polym. Sci., 20, 441-455 (1982), which are incorporated by referenceherein in their entirety. The composition to be analyzed is dissolved intrichlorobenzene and allowed to crystallize in a column containing aninert support (stainless steel shot) by slowly reducing the temperatureto 20° C. at a cooling rate of 0.1° C./min. The column is equipped withan infrared detector. An ATREF chromatogram curve is then generated byeluting the crystallized polymer sample from the column by slowlyincreasing the temperature of the eluting solvent (trichlorobenzene)from 20 to 120° C. at a rate of 1.5° C./min.

¹³C NMR Analysis

The samples are prepared by adding approximately 3 g of a 50/50 mixtureof tetrachloroethane-d²/orthodichlorobenzene to 0.4 g sample in a 10 mmNMR tube. The samples are dissolved and homogenized by heating the tubeand its contents to 150° C. The data are collected using a JEOL Eclipse™400 MHz spectrometer or a Varian Unity Plus™ 400 MHz spectrometer,corresponding to a ¹³C resonance frequency of 100.5 MHz. The data areacquired using 4000 transients per data file with a 6 second pulserepetition delay. To achieve minimum signal-to-noise for quantitativeanalysis, multiple data files are added together. The spectral width is25,000 Hz with a minimum file size of 32K data points. The samples areanalyzed at 130° C. in a 10 mm broad band probe. The comonomerincorporation is determined using Randall's triad method (Randall, J.C.; JMS-Rev. Macromol. Chem. Phys., C29, 201-317 (1989), which isincorporated by reference herein in its entirety.

Block Index

The ethylene/α-olefin interpolymers are characterized by an averageblock index, ABI, which is greater than zero and up to about 1.0 and amolecular weight distribution, M_(w)/M_(n), greater than about 1.3. Theaverage block index, ABI, is the weight average of the block index(“BI”) for each of the polymer fractions obtained in preparative TREF(i.e., fractionation of a polymer by Temperature Rising ElutionFractionation) from 20° C. and 110° C., with an increment of 5° C.(although other temperature increments, such as 1° C., 2° C., 10° C.,also can be used):

ABI=Σ(w _(i)BI_(i))

where BI_(i) is the block index for the ith fraction of the inventiveethylene/α-olefin interpolymer obtained in preparative TREF, and w_(i)is the weight percentage of the ith fraction. Similarly, the square rootof the second moment about the mean, hereinafter referred to as thesecond moment weight average block index, can be defined as follows.

${2^{nd}\mspace{14mu} {moment}\mspace{14mu} {weight}\mspace{14mu} {average}\mspace{14mu} B\; I} = \sqrt{\frac{\sum\left( {w_{i}\left( {{B\; I_{i}} - {A\; B\; I}} \right)}^{2} \right)}{\frac{\left( {N - 1} \right){\sum w_{i}}}{N}}}$

where N is defined as the number of fractions with BI_(i) greater thanzero. Referring to FIG. 9, for each polymer fraction, BI is defined byone of the two following equations (both of which give the same BIvalue):

${B\; I} = {{\frac{{1/T_{X}} - {1/T_{XO}}}{{1/T_{A}} - {1/T_{AB}}}\mspace{14mu} {or}\mspace{14mu} B\; I} = {- \frac{{{Ln}\; P_{X}} - {{Ln}\; P_{XO}}}{{{Ln}\; P_{A}} - {{Ln}\; P_{AB}}}}}$

where T_(X) is the ATREF (i.e., analytical TREF) elution temperature forthe ith fraction (preferably expressed in Kelvin), P_(X) is the ethylenemole fraction for the ith fraction, which can be measured by NMR or IRas described below. P_(AB) is the ethylene mole fraction of the wholeethylene/α-olefin interpolymer (before fractionation), which also can bemeasured by NMR or IR. T_(A) and P_(A) are the ATREF elution temperatureand the ethylene mole fraction for pure “hard segments” (which refer tothe crystalline segments of the interpolymer). As an approximation orfor polymers where the “hard segment” composition is unknown, the T_(A)and P_(A) values are set to those for high density polyethylenehomopolymer.

T_(AB) is the ATREF elution temperature for a random copolymer of thesame composition (having an ethylene mole fraction of P_(AB)) andmolecular weight as the inventive copolymer. T_(AB) can be calculatedfrom the mole fraction of ethylene (measured by NMR) using the followingequation:

Ln P _(AB) =α/T _(AB)+β

where α and β are two constants which can be determined by a calibrationusing a number of well characterized preparative TREF fractions of abroad composition random copolymer and/or well characterized randomethylene copolymers with narrow composition. It should be noted that αand β may vary from instrument to instrument. Moreover, one would needto create an appropriate calibration curve with the polymer compositionof interest, using appropriate molecular weight ranges and comonomertype for the preparative TREF fractions and/or random copolymers used tocreate the calibration. There is a slight molecular weight effect. Ifthe calibration curve is obtained from similar molecular weight ranges,such effect would be essentially negligible. In some embodiments asillustrated in FIG. 8, random ethylene copolymers and/or preparativeTREF fractions of random copolymers satisfy the following relationship:

Ln P=−237.83/T _(ATREF)+0.639

The above calibration equation relates the mole fraction of ethylene, P,to the analytical TREF elution temperature, T_(ATREF), for narrowcomposition random copolymers and/or preparative TREF fractions of broadcomposition random copolymers. T_(XO) is the ATREF temperature for arandom copolymer of the same composition (i.e., the same comonomer typeand content) and the same molecular weight and having an ethylene molefraction of P_(X). T_(XO) can be calculated from LnPX=α/T_(XO)+β from ameasured P_(X) mole fraction. Conversely, P_(XO) is the ethylene molefraction for a random copolymer of the same composition (i.e., the samecomonomer type and content) and the same molecular weight and having anATREF temperature of T_(X), which can be calculated from LnP_(XO)=α/T_(X)+β using a measured value of T_(X).

Once the block index (BI) for each preparative TREF fraction isobtained, the weight average block index, ABI, for the whole polymer canbe calculated.

Mechanical Properties—Tensile, Hysteresis, and Tear

Stress-strain behavior in uniaxial tension is measured using ASTM D 1708microtensile specimens. Samples are stretched with an Instron at 500%min⁻¹ at 21° C. Tensile strength and elongation at break are reportedfrom an average of 5 specimens.

100% and 300% Hysteresis is determined from cyclic loading to 100% and300% strains using ASTM D 1708 microtensile specimens with an Instron™instrument. The sample is loaded and unloaded at 267% min⁻¹ for 3 cyclesat 21° C. Cyclic experiments at 300% and 80° C. are conducted using anenvironmental chamber. In the 80° C. experiment, the sample is allowedto equilibrate for 45 minutes at the test temperature before testing. Inthe 21° C., 300% strain cyclic experiment, the retractive stress at 150%strain from the first unloading cycle is recorded. Percent recovery forall experiments are calculated from the first unloading cycle using thestrain at which the load returned to the base line. The percent recoveryis defined as:

${\% \mspace{14mu} {Recovery}} = {\frac{ɛ_{f} - ɛ_{s}}{ɛ_{f}} \times 100}$

where ε_(f) is the strain taken for cyclic loading and ε_(s) is thestrain where the load returns to the baseline during 1^(st) unloadingcycle.

While the invention has been described with respect to a limited numberof embodiments, those skilled in the art, having benefit of thisdisclosure, will appreciate that other embodiments can be devised whichdo not depart from the scope of the invention as disclosed herein.Accordingly, the scope of the invention should be limited only by theattached claims.

1. A process for forming a carpet comprising the steps of: selecting asubstrate; selecting an aqueous dispersion comprising: (A) at least onebase polymer, wherein said base polymer is a thermoplastic polymer; and(B) at least one stabilizing agent; and (C) at least one filler; and (D)water; applying said aqueous dispersion to at least one surface of saidsubstrate; thereby forming a film associated with said substrate,wherein said film comprises: a continuous base polymer phase; and adiscrete stabilizing agent phase dispersed in said continuous basepolymer phase.
 2. The process of forming a carpet according to claim 1,wherein at least one base polymer is selected from the group consistingof an ethylene-based co-polymer and a propylene-based co-polymer.
 3. Theprocess of forming a carpet according to claim 1, wherein the polymericstabilizing agent is different from the at least one said base polymerand is compatible with the at least one base polymer and the at leastone filler, and wherein the dispersion has filler in the range ofgreater than 0 to about 600 parts per hundred parts of a combined amountof the at least one base polymer and the polymeric stabilizing agent. 4.The process of forming a carpet according to claim 1, wherein the atleast one base polymer comprises about 35 percent to 55 percent byvolume of the aqueous dispersion.
 5. The process of forming a carpetaccording to claim 1, wherein the stabilizing agent comprises at leastone neutralized polar polymer.
 6. The process of forming a carpetaccording to claim 1, wherein the polar polymer comprises at least oneselected from a polyolefin having a polar group as co-monomer and apolyolefin having a polar group as grafted monomer.
 7. The process offorming a carpet according to claim 1, wherein the combined amount ofthe at least one base polymer and the polymeric stabilizing agentcomprises about 1 to about 74 volume percent of the aqueous dispersion.8. The process of forming a carpet according to claim 1, wherein theaqueous dispersion has a pH from about 6 to about
 14. 9. The process offorming a carpet according to claim 1, wherein the aqueous dispersionhas an average particle size diameter in the range of from about 0.3 toabout 3.0 microns.
 10. The process of forming a carpet according toclaim 1, wherein said aqueous dispersion further comprises at least awetting agent, a surfactant, an anti-static agent, a neutralizing agent,a frothing agent, a thickener, a rheology modifier, a biocide, or afungicide.